Method and apparatus for packaging merchandise



Nov. 17, 1959 R. D. MAYNARD, JR

METHOD AND APPARATUS FOR PACKAGING MERCHANDISE Filed March 29, 1955 3 Sheets-Sheet l DOCL WITH JOHN noss PAC LIFETIME I ALLWINUM ALLOY 20 2/ JOHN DOE HAWARE co, u.s.A

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.II In 1 INVENTOR. RALPH D. MAYNARD, JR.

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Nov. 17, 1959 R. D. MAYNARD, JR 2,912,805

METHOD AND APPARATUS FOR PACKAGING MERCHANDISE I Filed March 29, 1955 3 Sheets-Sheet 2 RALPH D. MAYNARD, JR.

v ATTORN Nov. 17, 1959 R. D. MAYNARD, JR 2,912,805 METHOD AND APPARATUS FOR PACKAGING MERCHANDISE Filed March 29, 1955 5 Sheets-Sheet 3 if J 2K? INVENTOR. RALPH D, MAYNARD, JR.

ATTORNEY a 42 I\\ z\\\\\\\\\\\\\\\\\\\\\\\\ United States Patent 2,912,805 METHOD AND APPARATUS FOR PACKAGING MERCHANDISE Ralph D. Maynard, Jr., Geneva, Ohio, assignor, by mesne assignments, to Washington Steel Products, Inc., Tacoma, Wash., a corporation of Washington Application March 29, 1955, Serial No. 497,500

' 8 Claims. (Cl. 53-37) This invention relates to the packaging of merchandise.

More specifically, the invention provides a novel method and apparatus for producing the package. The invention is especially useful for merchandise articles of an irregular form, and by way of example, has been disclosed herein as applied to hardware articles but without any intention of limiting the invention solely to that particular use.

An object of the invention is to provide a method of packaging in which the merchandise is mounted on a relatively stiff support card with a single film-type sheet forming an impervious transparent protective cover or skin extending over the merchandise in shape-conforming engagement therewith and adherently connected to the card, such that the merchandise and card are visible through the skin and are protected by the latter from dust and from becoming soiled or smeared during storage or handling.

Another object is to provide such a packaging method in which the merchandise or article is connected with the support card solely by the film sheet and can be released from the card in a clean condition by a simple tearing or stripping of the film sheet, the card preferably having a porous-surface characteristic and an adhesion-producing coating thereon for increasing the strength of the adherent connection between the film sheet and the card. I

A further object is to provide such a packaging method in which the film sheet is a heat-sensitive sheet and is rendered more or less soft, pliable and elastic by heating and is processed into its covering relation to the merchandise and card by pressure applied to the heated sheet, the pressure preferably being a fluid pressure differential between opposite sides of the film sheet obtainable ,by applying suction to the underside of the sheet through one or more openings of the card.

Still another object is to provide a packaging method of the character mentioned above in which the support card has openings therein defining an enclosure area and in which the film sheet extends over, and is adherentl'y connected with, the card with portions of the film sheet rising above the enclosure area and defining a hollow cover for retaining the merchandise thereagainst.

Yet another object is to provide such a packaging method in which the portions of the film sheet rising above the openings of the card are molded to form side walls of a pocket having the enclosure area as its floor, and in which one or more merchandise articles disposed in the pocket are retained therein by a cover sheet portion extending across the pocket and formed by a portion of the film sheet, the cover sheet portion preferably having a shape-conforming engagement with the merchandise for substantially preventing shifting thereof in the pocket.

As a further object, this invention provides a packaging method of the kind above indicated in which one or more positioning elements of a die extend through openings of the support card for locating the article or articles thereon, and in which the film sheet is processed over the card and articles while the latter are thus positioned on the card, after which the positioning elements are with drawn from the card openings.

It is likewise an object of this invention to provide a merchandise packaging method in which the positioning elements inserted through the card openings define an article-receiving pocket, and in which the film sheet is processed onto the card with portions of the film sheet being molded against the positioning elements to form the side walls of the pocket with another portion of the film sheet forming a cover sheet for the pocket, the removal of the support card from thedie causing the positioning elements to be withdrawn from the card openings.

As still another object, this invention provides novel apparatus for carrying out the packaging method above referred to in which a die plate adapted to receive the support card thereon has projecting locating elements of a height to extend through the openings of the card for positioning the articles being mounted on the card, the.

apparatus also comprising means for heating the film sheet and means for applying suction to the heated film sheet through the card openings.

Additionally, this invention provides packaging apparatus of the character mentioned just above in which the locating elements of the die plate comprise a group of such elements for defining an article-receiving pocket having aportion of the card as its floor and over which elements and pocket the film sheet is processed for forming a hollow cover over the articles.

The invention can be further briefly summarized as consisting in certain novel steps of procedure and in certain novel combinations and arrangements of parts as are hereinafter described in detail and set out in the claims hereof.

In the accompanying sheets of drawings forming a part of this specification:

Fig. l is a top plan view showing a merchandise package produced by the method and apparatus of this invention;

Fig. 2 is a side elevation of the package;

Fig. 3 is a partial transverse section taken through the package on section line 3-3 of Fig. 1;

Fig. 4 is another partial transverse section taken through the package on section line 44 of Fig. 1;

Fig. 5 is still another partial transverse section taken on section line 55 of Figll;

Fig. 6 is a fragmentary view showing a portion of the package on a larger scale;

Fig. 7 is a side elevation somewhat diagrammatic in form and showing packaging apparatus with which a merchandise package can be produced by the method of this invention;

Fig. 8 is a partial plan view of the die plate of the apparatus with the support card and merchandise articles thereon in position for the processing of the film sheet thereover; Y

Fig. 9 is a partial side elevation of the die plate with the support card and merchandise articles thereon and also showing the film sheet prior to the processing thereof onto the articles and card;

Fig. 10 is a partial side elevation similar to Fig. 9 but showing the. film sheet processed onto the articles and card;

Fig. 11 is a plan view of the die plate; and

Fig. 12 is a partial transverse section taken through the die plate and die-supporting structure substantially as indicated by section line 12-l2 of Fig. 11 and further illustrating the construction of the die plate and the mounting therefor.

The merchandise package ll) produced by the method and apparatus of this invention 'will be described first and, in general, comprises both a package having the merchandise contained therein and a display means by which the merchandise can be displayed to best advantage for'sales purposes. The package it) which is here shown by way of example comprises a relatively stiff backing sheet or support card 11, a merchandise article 12 carried by the card, and a film sheet 13 extending in continuous relation over the article and card and adherently connected to the card for attaching the article in a mounted relation thereto.

In the embodiment of the package shown in Figs. 1 to 6 inclusive, the merchandise article 12 is a hardware item of an irregular shape. The particular hardware item shown in Figs. 1 and 2 is a handrail bracket comprising a metal bracket member 14 and its attaching strap 15. The merchandise contained in the package It is here shown as also comprising a group of loose articles in the form of wood screws 16 for attaching the bracket member 14 to a wall and wood screws 17 for connecting a handrail with the strap 15. The handrail bracket 12 and the screws 16 and 17 are here shown merely by way of example of articles which can be packaged in accordance with the present invention and it will be understood, of course, that the invention is applicable to a great number and wide variety of other merchandise articles.

The support card 11 is preferably of paper, cardboard, or other fibrous sheet material, and is of a sufiicient stiffness to retain its substantially fiat shape even though the hardware item or items mounted thereon may be of substantial weight, such as the above-mentioned handrail bracket 12. A paperboard mounting card made from hardwood fibres and here represented by the support card 11, has been found to be very satisfactory for the packaging purposes of the present invention.

The support card 11 is here shown as having indicia printed on the upper face thereof relating to the merchandise contained in the package. Such printed indicia may comprise an identifying name 19 for the merchandise article, a designation 20 of the material of which it is made, a designation 21 of the name of the manufacturer or vendor, a designation 22 in the way of instructions for using the merchandise article, and a designation 23 for indicating the selling price of the article.

When the merchandise article 12 has one or more projecting portions thereon, such as the base flange 24 of the bracket member 14 and which might prevent the article from lying closely adjacent the upper or front face of the support card lll, the card can be provided with a suitable opening, such as the slot 25 into which a portion of the base flange 24 extends. The opening 25 also serves an important function in connection with the processing of the film sheet 13 onto the support card 11, as will be explained hereinafter.

When the support card 11 does not require such an opening 25 for accommodating a portion of the merchandise article, the card is provided with one or more other openings 26. If desired, one or more of the openings 26 can be provided in addition to the opening 25.

The film sheet or skin 13 extends in continuous relation over the upper face of the support card 11 and over the merchandise article or articles thereon. The film sheet 13 conforms to the irregular shape of a substantial portion of the merchandise article 12 and has a substantially skin-tight engagement with those portions along which it extends. Portions of the film sheet 13 also extend over the upper surface of the support card 11 in a fiat face-to-face engagement therewith and are adherently connected to the card surface.

The manner in which the film sheet 13 conforms to the shape of the merchandise article 12 is shown in Figs. 2 to 6 inclusive, from which it will be seen that the film sheet follows the contour of the various portions of the merchandise article by lying closely thereagainst with portions of the film sheet extending, to some extent, around and beneath certain portions of the merchandise article as shown in Fig. 5.

The film sheet 13 adheres strongly to the support card 11 as a skin or film extending over the major portion of the upper face of the card and, by reason of the strong adherent attachment of the fihn sheet to the card and the close-fitting engagement of the film sheet with the merchandise article 12, it will be seen that the film sheet connects the merchandise article securely to the card, such that the article will be retained on the card until it is intended to be removed therefrom and, while on the card, will be held against substantially any movement of the article relative to the card.

The film sheet 13 is a substantially impervious transparent plastic sheet, for example, a sheet of cellulosic material, such as cellulose acetate, cellulose acetate butyrate or the like and can be on the order of 10 mils in thickness. The film sheet 13 is also a heat-sensitive sheet material which can be rendered soft, pliable and somewhat elastic by the application of heat thereto. When the film sheet 13 has been heated sufficiently to render the same soft, pliable and somewhat elastic, it can be readily processed into the above-described substantially skin-tight shape-conforming engagement with the merchandise article 12 and into the flat adherent engagement with the surface of the support card 11.

Since the film sheet 13 forms a connecting means and cover for the merchandise article 12 and the support card 11 which is transparent, the article and the indicia printed on the support card can be readily seen through the film sheet by a prospective purchaser inspecting the merchandise package. Likewise, since the film sheet is impervious and has a smooth and glossy surface characteristic, dust or other foreign matter will not be likely to adhere to the package, and hence, the liklihood of the merchandise or card becoming smeared or soiled is substantially eliminated. Because of these protective characteristics of the film sheet 13, the package It) will retain a clean and satisfactory appearance for a considerable period of time during which the merchandise will be displayed to maximum advantage to customers.

The film sheet 13, although relatively tough and strong and having a normally tight adherence to the support card 11, can however, be stripped from the card and merchandise article by a stripping action started on the film sheet at a point adjacent an extreme edge of the support card. Such stripping of the film sheet from the card immediately releases the merchandise article for its intended use. The film sheet 13 does not adhere to the article itself but has a holding action on the article primarily by reason of its shape-conforming and substantially skin-tight engagement therewith.

For increasing the adhesive connection of the film sheet 13 with the upper face of the support card 11, such upper face is provided with a so-called heat-seal coating 28. The coating 23 is an adhesion-producing coating of a heatsensitive character in that it becomes tacky upon being heated. When the coating 28 has thus been rendered tacky by heating thereof, the pressing of the film sheet 13 against the face of the support card will result in a strong adhesive connection therebetween.

The heat-sensitive coating 28 can be a relatively thin layer of a suitable adhesive, such as a lacquer or pyroxylin. The heat-sensitive coating 28 can be applied to the surface of the support card 11 by spraying thereon in a liquid form, or by means of a roller device, or by brushing. The coating 28 unites strongly with the support card and forms a connecting medium between the card and the film sheet 13.

The attachment of the film sheet 13 to the support card 11 can be further strengthened by employing for the support card a sheet material having a porous surface characteristic. When the support card has such a porous surface characteristic, the heat-softened film sheet 13 will become interlocked with the porous support card during the processing of the film sheet thereon. When a support card having such a porous surface characteristic is also treated with the heat-sensitive coating material 28, that material becomes impregnated into the support card to further strengthen the adhesive connection between the film sheet and the card. A. fibrous support card, such as one made from the above-mentioned hardwood fibers, has this desirable porous surface characteristic.

When the merchandise article being mounted on the card has one or more openings formed in portions of the article lying adjacent the card surface, such as the openings 30 of the connecting strap 15, corresponding portions of the film sheet 13 extend into such openings and are adherently connected with the support card through such openings. The portions of the film sheet which are thus connected with the card through the openings 3110f the merchandise article, also serve to connect the article to the card in a manner which prevents any relative shifting between the article and the card.

When the merchandise contained in the package consists of, or includes, a plurality of loose individual articles such as the screws 16 and 17, the package is constructed so as to include a hollow cover member 31 by which such loose articles are securely held adjacent an enclosure area 32 of the support card 11. The cover member 31 is formed by shaped or molded portions of the film sheet 13 and comprises molded Wall and cover portions 33 and 35. The wall portions 33 are hollow and extend above the surface of the support card 11 and form side walls of a pocket 34 in which the articles 16 and 17 are disposed. The floor'of the pocket 34 is formed by the enclosure area 32 of the card which is surrounded, or partially surrounded, by the upstanding side walls 33.

The cover portion 35 extends across the pocket 34 and is formed by another portion of the film sheet 13 which is integrally connected with the portions of the film sheet which define the side walls 33. The cover sheet 35 extends down into the pocket 34 for varying distances by reason of its having a shape-conforming engagement with the articles 16 and 17 and by reason of the fact that portions of the cover sheet also extend down into existing spaces between the articles in the pocket. The cover sheet 35 retains the articles 16 and 17 in thepocket 34, and also by reason of its shape-conforming engagement with the articles, holds the same against shifting or rattling in the pocket.

The merchandise package 10 can be produced as anindividual package or, as described hereinafter, can be produced in a connected relation to other similar packages by the use of a support card of large area and from which support card the individual packages are severed after the film sheet 13 has been processed over the articles and support card. The lines of severance for separating the individual merchandise packages correspond in location with the broken lines 36 of Fig. 8.

If desired, the support card of the package 10 can be provided with a suitable opening or slot 37 adjacent one edge thereof for use in hanging the merchandise package, or a group of such packages, on a hook or on a suitable projection of a wall or rack.

Many of the advantages of the merchandise package 10 have already been described above, but in general it will now be understood that the package represents a very satisfactory and economical way of packaging hardware articles or other merchandise items, such that they will be visibly and strikingly displayed to prospective purchasers and, at the same time, the articles and the display card will be effectively protected against dust and against soiling or smearing which would detract from the attractive appearance of the merchandise. It will now also be seen that the transparent impervious heat-sensitive film sheet with its skin-tight engagement with the merchandise article and its strong adherent connection to the surface of the support card, firmly attaches the merchandise article to the card in a manner to prevent relative shifting therebetween, but still permits the merchandise to be readily removed from the card by a tearing or stripping away of the film sheet.

The packaging method and packaging apparatus of this invention are illustrated to best advantage in Figs. 7 to 12 inclusive and will be described in greater detail hereinafter. The packaging apparatus maybe in the embodi merit of the vacuum-forming machine 40 shown in Fig. 7 and which includes a die plate 41 removably received on a stationary die support 42. The machine 40 also in cludes a support frame 43 for supporting the film sheet material 13 above the die plate 41, and a heating unit 44 located above the frame 43. The machine 40 is also provided with a base 38 and a suitable frame structure 39 rising above the base and supporting the various components of the machine.

The construction of the die plate 41 and the die mount 42 are further illustratedin Figs. 11 and 12 from which it will be seen that the die plate 41 comprises a rigid base plate 45 and plate sections, or blocks, 46 lying in edge-abutting relation to each other and mounted on the upper surface of the base plate by attaching screws 47. The die plate 41 also includes edge strips 48 surrounding the plate sections 46 and secured to the base plate 45 by the screws49.

The plate sections 46 are preferably quadrangular in shape and areof a size corresponding with the plan dimensions of the support card 11 of the merchandise packages to be produced. Each of the plate sections 46 is used in the processing operation to form one of the merchandise packages 10. -In the die plate 41 here shown, the

plate section 51 is of a size, shape and construction suitable for producing the above-described merchandise package 10.

As shown in Figs. 11 and 12, the plate section 51 has asr'nooth fiat upper surface 52 which is provided with a slot 25 corresponding in shape and location with the opening 25 of the support card 11. The plate section 51 is also provided with a group of positioning elements 53 .in the form of flange-like projections extending above the surface 52 in an arrangement to define an enclosure corresponding with the pocket 34 of the above-described merchandise package 10. The positioning elements 53 are suitably secured to the plate section 51 as by welding or. the like, or can be formed as a part of the plate section itself, and define a wall or barrier which extends around the pocket 34 and which is interrupted by the vertical slots 54.

As a preparatory step'in forming the merchandise package 10, a support card sheet 11 of a size suitable for producing several of the packages is placed on the die plate 41 in overlying relation to the plate sections 46 thereof, with the opening 25 of the card sheet registering substantially with the slot 25* of the plate section 51 and with the locating projections 53 extending. into and through a group of corresponding openings or slots 55 cut in the support card sheet. The portions 56 of the card sheet which remain intact between the adjacent ends of the openings 55 are received in the vertical slots 54 when the support card sheet is placed on the die plate.

From the construction of the die plate and the placing of the support card sheet 11* thereon, as thus far described, it will be seen that the locating projections 53 will extend into and through the group of card sheet openings 55 and will surround the above-mentioned enclosure area 32 of the card to define the pocket 34 which has the enclosure are-a 32 as its bottom wall or floor. The merchandise articles are now placed on the support card sheet 11 so as to lie on, or against, the upper face thereof. When thus applied to the support card sheet 11*, the merchandise article 12 occupies the relative position shown in Fig. 1 and the loose articles represented by the screws 16 and 17 are disposed in the pocket 34.

Although the construction of the die plate 41 has been described in detail above only for the plate section 51, which is used in producing the merchandise: package 10,

the various other-plate sections of the die plate have structural characteristics suitable for the particular merchandise items of the packages to be produced thereon. Thus, the plate section 57, which is used in producing a merchandise package 58 having articles therein which include wire springs 59, has locating elements thereon in the form of shouldered pins 60 which project from the die plate and are used in positioning the springs adjacent the upper face of the card sheet 11 during the processing of the film sheet 13 over the merchandise articles and card.

The locating pins 60 comprise a cylindrical lower body portion 61 of a relatively large cross-sectional size which extends into, and through, an opening 62 of the support card sheet, and an extension stem 63 of relatively reduced size on which a hook end 59 of one of the wire springs 59 is adapted to be hooked. As thus supported by the pin 60, the spring 59 will be held in a relatively straight position adjacent the support card sheet and will also be maintained slightly above the surface of the card sheet by reason of the hook end resting on the shoulder formed by the upper end of the body portion 61 of the locating pin 60.

Similarly, various other plate sections 62 of the die plate 41 are provided with groups of positioning elements 62 corresponding with the flange-like positioning elements 53, but having a specifically difierent enclosure arrangement depending upon the shape of the article-receiving pocket to be defined adjacent the surface of the support card sheet. Still other plate sections 63 have article-positioning elements projecting thereabove in the form of groups of straight slender pins 63.

The die plate 41 is supported in the machine 40 by the die mount 42 which has a suction box or manifold 65 therein. For a purpose to be presently explained, the plate sections 4-6 of the die plate 41 have openings 66 therein which are in communication with the suction box 65 through correspondingly located openings 67 of the base plate 45. The machine 40 also includes a suctionproducing pump or other source of suction or sub-atmospheric pressure (not shown), which is connected with the suction box 65 by the conduit 63.

A supply of film sheet material 13 for forming the film sheet 13 is contained in a roll 69 which is suitably supported on the front of the machine 40 and from which a strip of the film sheet material can be unwound. After the hardware items have been placed in the proper location on the support card sheet 11 overlying the die plate 41, a suitable length of the film sheet material 13 is unwound from the roll 69 and is placed in the support frame 43 by which it is supported at an elevation above the die plate 41, as shown in Fig. 6.

While the film sheet material 13 is thus supported in the frame 43, it is heated by heat supplied by the heating unit 44. When the film sheet material in the frame 43 has thus been heated sufficiently to render the same soft, pliable and somewhat elastic, the frame is lowered to cause the heated film sheet to rest on the hardware items and support card.

The heating of the film sheet material 13 is preferably carried out while this material is being supported in spaced relation above the die plate 41, as just described above, and the heating of the film sheet material can, if desired, be completed While the sheet is thus supported or can be continued while this material is in engagement with the articles 12 and the card sheet 11 Substantially simultaneously with the lowering of the heated film sheet material 13 into engagement with the hardware articles, the source of suction is rendered effective on the underside of the heated film sheets through the conduit 68, the suction box 65, the die plate passages 67 and 66, and through the various openings of the support card sheet 11 including the above-mentioned openings 25, 26 and 55. The pressure differential thus created between the opposite sides of the film sheet 13 causes the sheet to be pressed aginst the hardware items and against the upper surface of the support card 11 with a substantially skin-tight engagement thereaginst. Portions of the film sheet are thereby molded or contoured to the abovedescribed shape-conforming engagement with portions of the hardware items, and other portions of the film sheet are flatly pressed aginst the support card and are adherently connected to the latter.

During such pressing and molding of the heat-softened film sheet, portions thereof become draped over, and molded against, the hardware items and the group of positioning elements 53 of the mold plate 41. The portions of the film sheet which are draped and molded over the positioning elements 53, form the above-described hollow cover member 31 in confining and holding engagement with the articles 16 and 17 contained in the pocket 34.

The construction of the machine 419 will now be further described. As shown in Fig. 7, the frame 43 is a centrally-open frame formed by two hingedly connected upper and lower frame sections 71 and 72 between Which the length of the film sheet material 13 is adapted to be placed and gripped. The opening of the frame 43 is of such size and shape that when the frame is lowered around the die plate 41, the film sheet material 13 will engage and rest on the hardware items 12 and the support card sheet 11*. The upper frame section 71 has a handle 73 thereon for manipulating the frame and for swinging the upper frame section upwardly to an open position to permit the film sheet material 13 to be placed over the lower frame section '72, after which the upper frame section is swung downwardly to cooperate with the lower frame section in clamping the film sheet material therebetween.

For supporting the frame 43 above the die plate 41, the machine 40 is provided with a substantially horizontally extending track 74- formed by aligned front and rear track sections 74 and 74 The frame 43 is supported on the track 74 by suitable rollers 75 provided on the lower frame section 71 and which roll on the track. The frame 43 is movable along the track 74 onto the rear track section 74' to occupy a retracted position 4-3 while the die plate 41 is being placed on the die support 42. The support card sheet 11 and the merchandise articles 12, 16, 17 and 53 are preferably placed on the die plate 41 while the latter is removed from the machine to constitute a loaded die plate as represented in Fig. 8. The movement of the frame 43 to its retracted position 43 not only permits the loaded die plate to be introduced into the machine 40, but also permits free access to the die plate for stripping the support card sheet 11 therefrom after the processing of the film sheet material 13 over the articles.

When the loaded die plate 41 has been introduced into the machine All the frame 43 is moved forwardly onto the front track section 74 and the film sheet material 13 is placed in the frame in the manner explained above.

The heating unit 44 is supported on an upper track 76 by suitable rollers 77 and is movable along the track to a forward heating position over the frame 43 in which the heating unit is shown in full lines in Fig. 7. The heating unit 44 is movable to a rear position M on the track '76 and occupies that position when the loaded die plate 41 is being placed in the machine and when the upper member 71 of the frame 43 is to be swung to its open position for placing the film sheet material 13 in the latter.

The heating unit 44 can be of any suitable construction and may comprise a box-like member having a downwardly facing opening through which heat can be directed onto the film sheet material 13 being supported in the frame 43 by a resistance-type electric heating element '78. A handle 44 on the front of the unit 44- facilitates the movement thereof on the track 76. Heat from the unit 44 is also applied to the heat-sensitive coating 28 of the support card sheet 11 for rendering such coating tacky, for the attachment of the film sheet to the support card as explained above.

The lowering of the frame 43 for bringing the heated film sheet material 13 into engagement with the hardware articles and the card sheet can be accomplished by a downward movement of the front track section 74 with the frame thereon. The front track section 74 is adapted to be raised and lowered by suitable means, such as by pairs of double-acting pressure fluid cylinders '79 and 80 provided on the frame structure 39 at opposite sides of the machine and having pistons 79 and 80 operable therein. The track section 74 is connected with the pistons of the cylinders 79 and 80 by the upwardly extending piston rods 81 and 82.

From the accompanying drawings and the foregoing detailed description, it will now be readily understood that this invention provides a novel method and apparatus for producing a merchandise package of the kind in which the merchandise is carried by a support card and is displayed to advantage through a transparent protective film which secures the merchandise to the card but is adapted to be readily stripped or torn away to release the merchandise. Additionally, it will now be understood that the invention also provides a novel method and apparatus for processing a heat-sensitive film sheet over the merchandise and support card in forming the package.

Although the invention has been illustrated and described in detail herein, it should not be regarded as being limited correspondingly in scope since it is intended to be inclusive of all variations and modifications coming within the terms of the claims hereof.

Having thus described my invention, I claim:

1. The method of packaging which comprises, providing a relatively stiff support card having a group of openings therein defining -an enclosure area, projecting a barrier means through said openings so as to define a pocket on the upper face of the card having said enclosure area as its floor, placing merchandise in said pocket, placing a heat-sensitive film sheet to extend across said pocket and card, heating said sheet to render the same soft and pliable, molding portions of said sheet against said barrier means and merchandise for forming side and top walls for said pocket, adhering other portions of said sheet to said upper surface adjacent said enclosure area, and withdrawing said barrier means from said openings.

2. The method of packaging which comprises, providing a relatively stiff support card having a group of openings therein defining an enclosure area, projecting a barrier means through said openings so as to define a pocket on the upper face of the card having said enclosure area as its floor, placing articles in said pocket, placing a heat sensitive film sheet to extend across said pocket and card, heating said sheet to render the same soft and pliable, creating a fluid pressure differential between opposite sides of said sheet by applying suction to the underside of the sheet through said openings and thereby pressing portions of the sheet into shape-conforming engagement with said barrier means and articles to form side and top walls for said pocket with the top wall substantially holding the articles against shifting in said pocket and thereby also pressing other portions of said sheet flatly against said upper surface adjacent said enclosure area for connecting said sheet 'with the card and forming a substantially skin-tight adherent film on said upper surface, permitting the softened sheet to cool and harden, and withdrawing said barrier means.

3. In a method of mounting hardware articles on a relatively stiff display card having openings therein, the steps of extending locating elements through said openings from the underside of said card, placing an article on the upper face of said card and in engagement with said locating elements, placing a heat-softenable film sheet to extend across said article and card, heating said sheet to soften the same, creating a fluid pressure differential between opposite sides of said sheet by applying suction to the sheet through said openings and thereby pressing portions of the softened sheet into shape-conforming substantially skin-tight covering engagement with portions of said article and thereby also pressing other portions of the softened sheet flatly and adherently against areas of said upper face surrounding said article for connecting said sheet and article with the card and forming a substantially skin-tight film on said upper face, permitting the softened sheet to cool and harden, and withdrawing said locating elements from said openings.

4. in apparatus for packaging merchandise, a die plate adapted to receive thereon an article support card having 4 preformed openings therein in surrounding relation to a supporting area, and locating elements projecting from said die plate of a height to extend into and through said openings from the underside of said card for use in confining articles in said area and adjacent the upper face of said card, said elements comprising a group in a plan arrangement of substantially the same size and shape as said support area.

5. In apparatus for packaging merchandise, a die plate adapted to receive thereon an article support card having preformed openings therein in surrounding relation to a support area, said die plate having a passage for fluid extending therethrough, locating elements projecting from said die plate of a height to extend into and through said openings from the underside of said card for use in confining articles in said area and adjacent the upper face of said card, said elements comprising a group in a plan arrangement of substantially the same size and shape as said support area, and means for applying suction to said openings from the underside of said card and through the fluid passage of said die plate.

6. In apparatus for mounting hardware articles on a support card having openings therein, a die plate adapted to receive said card thereon, means for supporting a heatsoftenable film sheet above said die plate and for lowering said sheet onto said articles and card, means for heating said sheet, said die plate having locating elements projecting therefrom of a height to extend into and through said openings for locating the articles adjacent the upper face of said card, and means for applying suction to said sheet through the openings of said card.

7. In apparatus for packaging merchandise, a die plate adapted to receive thereon an article support card having a group of openings therein defining an enclosure area, and a group of locating elements projecting from said die plate of a height to extend into and through said openings, said elements having a plan arrangement of substantially the same size and shape as said enclosure area and defining with said card an article-receiving pocket having said enclosure area as its floor.

8. In apparatus for mounting articles on a support card having a group of openings therein defining an enclosure area on the upper face of the card, a die plate adapted to receive said card thereon, means for supporting a heatsoftenable film sheet above said die plate and for lowering said sheet onto said card, means for heating said sheet, said die plate having a group of locating elements projecting therefrom of a height to extend into and through said openings, said elements defining with said card an article-receiving pocket having said enclosure area as its floor, and means for applying suction to said sheet through said openings for molding portions of said sheet against said element to form walls for said pocket.

References Cited in the file of this patent UNITED STATES PATENTS 1,647,289 Gwinn Nov. 1, 1927 1,856,694 De Correvont May 3, 1932 1,980,022 Whitehouse Nov. 6, 1934 2,278,524 Parker Apr. 7, 1942 2,486,759 Pfeiifer Nov. 1, 1949 2,618,383 Chapman et al Nov. 18, 1952 2,621,129 Ramsbottom et a1. Dec. 9, 1952 2,623,338 Riemer Dec. 30, 1952 2,690,593 Abercrombie Oct. 5, 1954 2,750,719. Wandelt June 19, 1956 FOREIGN PATENTS 1,048,145 France Dec. 21, 19.53 

